Flameproof and fireproof resinous foams

ABSTRACT

FLAMEPROOF AND FIREPROOF RESINOUS FOAMS ARE PRODUCED BY REACTING TOGETHER THE FOLLOWING ADMIXED COMPONENTS: (A) THE LIQUID POLYMERIC PRODUCTS OF A HEATD BLEND OF A REDUCING SUGAR, PHOSPHORIC ACID, ONE OR MORE FLUIDIFIERS AND, PREFERABLY, A POLYHYDRIC PHENOL HAVING AT LEAST TWO HYDROXY GROUPS IN A META POSITION; (2) AT LEAST ONE FOAM ING, GELLING AND HARDENING AGENT, SUCH AS AN ORGANIC POLYISOCYANATE AND/OR A POWDER OF A POLYVALENT METAL AOVE CADMIUM IN THE ELECTROMOTIVE SERIES; AND PREFERABLY,BOVE AN DDITIONAL HARDENER, SUCH AS FORMALDEHYDE, FURFURYL ALCOHOL, OR BENDS OR POLYMERS OF FURFURYL ALCOHOL AND FORMALDEHYDE.

"United States Patent Office 3,824,200 Patented July 16, 1974 U.s.c1. 260--2.5 R 13 Claims component (1), when component (3) is present in the reaction mixture, is generally from about :1 to about 1:1.

The component (1) of the reaction mixture is the liquid polymeric product (or resin former) of a heated blend of (a) from about 25% to about 80% by weight, and preferably from about 37% to about 78% by weight, of a reducing sugar, (b) from about to about 62% by weight, and preferably from about 15% to about 35% by weight, of 85% strength phosphoric acid, (0) from about 2% to about 20% by weight, and preferably from ABSTRACT OF THE DISCLOSURE about 4% to about by weight, of at least one Flameproof and fireproof resinous foams are produced fiuldlfier and (d) from about to about 15% by by reacting together the following admixed components: Welght: and preferably f about to about 10% (1) the liquid polymeric products of a heated blend of a by welght of polyhydnc Ph havmg at least two reducing sugar, phosphoric acid, one or more fiuidifiers 15 droxy ,groups In a m Pst1n:'RePresentatwe examples and, preferably a polyhydric phenol having at least two of suitable reducing sugar include monosaccharides hydroxy groups in a meta position; (2) at least one foam and disaccharides, such as dextrose and commercial ing, gelling and hardening agent, such as an organic polyglucose produced by hydrolysis of Carbohydrates isocyanate and/or a powder of a polyvalent metal above ffuctose galaFmse t maltljse and the cadmium in the electromotive series; and, preferably, (3) P their blends.wlth hlgher sflcchandes Such as an additional hardener, such as formaldehyde, furfuryl found In Corn Syrup Wlth dextrose bemg preferredhclme alcohol, or blends or polymers of furfuryl alcohol and Sugar or p however cannot i usiedpecause It IS formaldehyde. non-reducing sugar. The phosphorlc acid is generally of 85% strength, although lower strength phosphoric acld can be used, provided compensation is made by a reduc- The present invention relates to flameproof and firetion of the free water present in the reaction mixture proof resinous foams and to processes for eir when water serves as a fluidifier of the reaction mixture. P paration. Suitable fiuidifiers include water and/or a dihydric or Foams have been produced heretofore by a variety of polyhydric lower aliphatic alcohol, such as ethylene techniques, such as by means of chemical blowing agents, glycol, propylene glycol, butylene glycol, diethylene the release of gas under pressure and the beating of air glycol, glycerol, and the like. The preferred fluidifier is into a foamable mass of an organic polymer, such as polywater. Useful polyhydric phenols having at least two hyvinyl chloride, polyurethane and the like. However, such droxy groups in a meta position include resorcinol, foams do not have the properties of being flameproof pyrogallol and phloroglucinol. The liquid polymeric and fireproof. component (1) is described in my US. Pat. No. 3,551,365 It is, therefore, the principal object of the present in- (incorporated by reference herein) and is a reducing vcntion to provide flameproof and fireproof resinous sugar copolymer or terpolymer containing chemically foams and to provide processes for their preparation. bound repeating acidic phosphate groups or units therein The process of the invention for the preparation of a and repeating phenolic groups or units, when the phenolic fiameproof and fireproof resinous foam comprises rereactant is used in its preparation. acting by mixing together the following components: (1) The liquid polymeric component (1) may be prepared the liquid polymeric product of a heated blend of (a) a by dissolving or dispersing the reducing sugar in the reducing sugar, (b) phosphoric acid, (c) at least one fluidifier, which generally is water. When the solution or fluidifier and, preferably and optionally, (d) a polyhydric dispersion is obtained, the polyhydric phenol, when used, phenol having at least two hydroxy groups in a meta posiis then added while stirring and this is followed by the tion; (2) at least one foaming, gelling and hardening addition of part or all of the phosphoric acid. The system agent, namely, (e) organic polyisocyanate and/or (f) a is brought to the boil (or below the boil when heating powder of a polyvalent metal above cadmium in the elecunder elevated Pressure) and maintained at about tromotive series; and, preferably and optionally, (3) an 0-130 C. for a period of 5 to 20 minutes or longer additional hardener. The component (2) is present in the after which it is cooled to ambient temperatures with the reaction mixture in an amount sufficient to cause foamfurther addition of any balance of the prosphoric acid. ing, gelling and hardening thereof while the preferable This system can be maintained at a higher temperature and optional component (3), when present, is present in as the initial water content is reduced. the reaction mixture in an amount sufiicient to cause addi- Representative examples of formulations used for pretional hardening thereof. The amounts of components paring the liquid polymeric component 1) by the above- (2) and (3) relative to the amount of component (1) described procedure are given in the following Table I present in the reaction mixture will vary appreciably d n Tables I and II of y 3,551,365 and are dependent primarily upon the chemical nature (incorporated by reference herein):

TABLE I Percent by weight Examplenumber 1 2 3 '4. 5 6 7 8 9 10 11 12 13 14 15 16 17 Components:

Reducing sugar, e.g., dextrose or commercial glucose- 28 48.4 57 62 63.5 64 64 67 72 77 so 57 69 65 69 57 Phosphoric acid (85%) 62 42.1 31 26 24.5 23 24 20 15 10 5 27 19 15 20 28.6 25 Water 4 3.5 6 6 3 2 3 3 3.5 4 t5 6 c 6 2.5 6 Ethylene glycol 5 3 4 3.5 3 4.5 9 Polyhydric phenol, e.g., resorcinoL 6 6 6 6 6 6 6 6 6 6 6 10 10 10 6 12 of these components, their reactivity and molecular weight. The weight ratio of component (2) to component As noted above, the component (2), i.e., a foaming,

and hardening agent, used in the process of the invention,

(1) in the reaction mixture is generally from about is (e) an organic polyisocyanate and/or (f) a powder of 0.01:1 to about 1:1 and usually is from about 0.4:1 to about 1:1, while the weight ratio of component (3) to a polyvalent metal above cadmium in the electromotive series. Suitable organic polyisocyanates include 3,3'-dimethyl 4,4 biphenylene diisocyanate, 4,4'-diphenyl methane diisocyanate (MDI), 2,4 toluene diisocyanate (TDI), 4,4'-diphenyl diisocyanate, paraphenylene diisocyanate, hexamethylene diisocyanate, 4,',4"-triisocya 4 further heat or bake the foam product at a temperature up to about 300 F. for up to about one hour to further expand the foam and to improve the thermal insulation properties thereof by removing the thermally conductive natio triphenyl methane, 1,3,5 triisocyanato ben- 5 fluidifier component (c) therefrom and to effect further zene, 2,4,6 tirisocyanato toluene, and the like. cross-linking and hardening. The powder of a polyvalent metal above cadmium in the The resinous foam products of the invention are charelectromotive series generally has a particle size rangacterized by their fiameproof and fireproof properties. ing'from about 100 mesh to about 400 mesh. Representa- The resinous foam products are generally of closed cell tive examples of suitable polyvalent metals include barstructure and vary in consistency from resilient foams ium, calcium, magnesium, aluminum, manganese, zinc to rigid foams having a wide range of tensile strength and iron. This component (2) serves the plural funcand compression resistance. tions of foaming, gelling and hardening the liquid poly- Flameproof and fireproof resinous foams were premeric product or component (1) into a fiameproof and pared following the above procedure by using the reacfireproof resinous foam by reacting with the chemically tion mixtures described in Table II below.

TABLE II Parts by Weight Example number 1s 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Reactants:

Liquid polymeric product of Example:

Aluminum powder. Magnesium powder. Iron powder Zinc powder Polyamide (Versamid 125) Zinc oxide Aluminum oxide- Paraformaldehyde Furfuryl alcohol-formaldehyde blend (647 /36 Furfuryl alcohol-formaldehyde polymer (84%/16%) 5 *MDI is 4,4-diphenyl methane diisocyanate. The pure form was used in Example 24, whereas crude MDI (Mondur MR) also containing a triisocyanate was used in Examples 18-23, 25 and 27.

bound acidic phosphate groups or units in the liquid polymer to liberate a gas (hydrogen or carbon dioxide) and to cross-link and harden the liquid polymeric product into a solid foam structure while preventing adverse foam collapse.

The component (3), i.e., an additional hardener for increasing the rate and/or degree of gelation and hardening, usable in the process of the invention is furfuryl alcohol, formaldehyde or a blend or polymer of furfuryl alcohol and formaldehyde or other aldehydes, such as glyoxal or furfural.

The process of the invention is conducted by mixing together the requisite components (1) and (2) with the optional, but preferred, component (3). If desired, other optional compatible adjuvants can be present in the reaction mixture, such as colorants, fillers, volatile solvents, Water repellents (e.g., urethane oils) metallic oxides, polyamides, polyamines, surfactants, carbonates, and the like. The reactants are mixed at a temperature from about 70 F. to about 200 F. at atmospheric pressure, although other equivalent correlated temperature and pressure conditions can be employed. The foaming, gelling and hardening of the reaction mixture occurs generaly during a time interval of from about 2 to about 10 minutes or longer. The mixing of the reactants should be thorough to insure greater uniformity of cell structure in the foam product. The rate of the reaction and the extent of the expansion can be increased, where desired, by conducting the reaction at an elevated temperature and pressure. After the reaction has occurred and the foam product has gelled and hardened, it is permitted to cool to room temperature. In some instances, it may be desirable to The resinous foams produced from the reaction mixtures described in Table II above were flameproof and fireproof and exhibited loW smoke evolution or smoke density and low weight loss upon the heating thereof. They varied in consistency from resilient foams to rigid foams having variable tensile strength and compression resistance.

The resinous foams of the invention are particularly useful in the formation of products where flameproof and fireproof or thermal insulation properties are desirable,- such as, in materials of construction used in buildings, furniture, automobiles and aircraft, and also in products where ablation resistance is desirable, such as in missile nose cones, and in coating applications.

It will be appreciated that various modifications and changes may be made in the process and product of the invention in addition to those mentioned above by those skilled in the art without departing from the essence of the invention and that accordingly the invention is to be limited only within the scope of the appended claims.

What is claimed is:

1. A process for the preparation of a flameproof and fireproof resinous foam which comprises reacting by mixing together at a temperature from about 70 F. to about 200 F. the following components:

(1) the liquid polymeric product of a heated blend of (a) from about 25% to about by weight of a reducing sugar,

(b) from about 5% to about 62% by weight 0 strength phosphoric acid,

(c) from about 2% to about 20% by weight of at least one fluidifier selected from the class consisting of water and dihydric and polyhydric lower aliphatic alcohols, and

(d) from about 0% to about by weight of a polyhydric phenol having at least two hydroxy groups in a meta position selected from the class consisting of resorcinol, pyrogallol and phloroglucinol; and

(2) at least one foaming, gelling and hardening agent which is a powder of a polyvalent metal above cadmium in the electromotive series; the component (2) being present in the reaction mixture in an amount suflicient to cause foaming, gelling and hardening thereof.

2. The process as defined by claim 1 wherein the reaction mixture further contains the following component:

(3) an additional hardener selected from the class consisting of furfuryl alcohol, formaldehyde, a blend of furfuryl alcohol and an aldehyde, and a furfuryl alcohol-aldehyde polymer; the component (3) being present in the reaction mixture in an amount sufficient to cause additional hardening thereof.

3. The process as defined by claim 1 wherein the weight ratio of component (2) to component (1) is from about 0.01:1 to about 1:1.

4. The process as defined by claim 1 wherein the weight ratio of component (2) to component (1) is from about 0.4:1 to about 1:1.

5. The process as defined by claim 2 wherein the weight ratio of component (3) to component (1) is from about 0:1 to about 1:1.

6. The process as defined by claim 1 wherein component 1) is the liquid polymeric product of a heated blend of (a) from about 37% to about 78% by weight of a reducing sugar,

(b) from about 15% to about 35% by weight of 85% strength phosphoric acid,

(c) from about 4% to about 15% by weight of at least one fluidifier selected from the class consising of water and dihydric and polyhydric lower aliphatic alcohols, and

(d) from about 3% to about 10% by weight of a polyhydric phenol having at least two hydroxy groups in a meta position selected from the class consisting of resorcinol, pyrogallol and phloroglucinol.

7. The process as defined by claim 3 wherein component (2) is aluminum, magnesium, iron, manganese or zinc powder.

8. The process as defined by claim 5 wherein component (3) is furfuryl alcohol.

9. The process as defined by claim 5 wherein component (3) is formaldehyde.

10. The process as defined by claim 1 wherein the foam is subsequently heated at a temperature up to about 300 F. for up to about one hour.

11. The fiameproof and fireproof resinous foam produced by the process defined in by claim 1.

12. The flameproof and fireproof resinous foam produced by the process defined by claim 2.

13. The flameproof and fireproof resinous foam produced by the process defined by claim 10.

References Cited UNITED STATES PATENTS 3,046,146 7/1962 Woodhead. et al 106-162 3,223,537 12/1965 Wiegert et a1. 10640 R 3,551,365 12/1970 Matalon 26017.2 3,255,125 6/1966 Block et al. 2602 P 2,525,107 10/1950 Whiting et a]. 260-2 P 2,409,774 10/ 1946 Mack et al. 2602 P 3,520,849 7/ 1970 Vandenberg 260-2 P WILBERT J. BRIGGS SR., Primary Examiner US. Cl. X.lR.

l06-122, 162; 117-l61 R; 2602 P, 2.5 FP, 17.2, 29.2 R, 33.4 R, 29.3, 47 R, 67 PA, 209 R, 829, DIG. 24

32 33 UNITED STATES PATENT OFFICE CERTIFICATE OF (IORRE CTDON Patent No. 3,824,200 Dated July 16, 1974 Inventor(s) Ralph Matalon It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 1, line 5, "Camden, N.J. 08034" should read Cherry Hill, N.J. 08034 line 14, "products" should read v-- product Column 2, line 15, "sugar" should read sugars lines 69 & 70, after "foaming" and before "and" insert rgelling Column 3, lines 4 & 5, "4',4"triisocyanatio" should read 4,4',4"tri isocyanato line 66, "generaly" should read generally Columns 3 & 4, Table II, after "Manganese Powder" and under the "Parts by Weight" caption reading "21" the figure "1" should be deleted; after "Iron Powder" and under the "Parts by Weight" caption reading "28" insert the figure Signed-and sealed this 8th day of October 1974.

(SEAL) Attest:

MCCOY M. GIBSON JR'. 1 c. MARSHALL DANN Attesting Officer Commissioner of Patents 

